SYMMETRIC HYDRAULIC LIFT

MODEL AMI 5,5 VAN - ML

(098000-ML-00)

INSTRUCTIONS FOR USE

BLL = 4000 mm / HG = 4900 mm

AUTO MOTIVE INDUSTRIAL a.s.

Sokolovská 1169, 570 01 LITOMYŠL
Tel.: +420 461 618 555
Fax.: +420 461 612 132
e-mail: [email protected]
www.automotive.cz
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TABLE OF CONTENTS
1. Scope and purpose
1.1 General
1.2 Schematic view of the lift
1.3 Technical data
1.4. Description
1.5. Wiring and hydraulic drawing

2. Assembly and installation

3. Principles of safe operation of the lift
3.1 Operating personnel
3.2 Vehicle drive
3.3 Lifting
3.4 Lowering
3.5 The forbidden handling and other things to avoid
4. Monitoring the safety devices
5. Maintenance
5.1 Steel cables tensioning procedure
6. Technical inspections
7. Troubleshooting
5.1 Motor failure
5.2 Motor works OK but the lift does not move up
5.3 The lift cannot be lowered
5.4 Other problems
8. Parts replacement
9. Decommissioning the equipment
10. List of delivered items

The information provided in these instructions has been checked carefully. However, it is impossible
to eliminate all contingent errors. These instructions are intended for users with technical knowledge
in the inspection of motor vehicles.

Technical and content changes reserved.

The Operating Instructions valid from 16th August, 2007

Version 01
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1. SCOPE AND PURPOSE

1.1 General
The hydraulic lift AMI 5,5 VAN ML is intended for lifting the lightweight trucks or vans with the
total weight not greater than 5,5 tons respectively.AMI 5,5 VAN ML is produced in several different
overall heights (see the dimension marked Hg in the following diagram) The variants with different
heights are produced in order to make a optimal choice possible in accordance with the exact needs of
our customers. AMI 5,5 VAN ML is produced in heights 4300 mm, 4600 mm and 4900 mm. In case
of these additional heights the product bears the marking AMI 5,5/4300, AMI 5,5/4600 and AMI
5,5/4900.

1.2 Schematic view of the lift

1.3 Technical data

Model: AMI 5,5 VAN ML AMI 5,5 4000 AMI 5,5-4300 AMI 5,5-4600 AMI 5,5-
4900/BL4000
Maximum capacity kg 5500 5500 5500 5500
Lifting time seconds 60 60 60 60
Lowering time seconds 20 20 20 20
Power supply — 3/N/PE AC 400V/230V/50Hz
Electric motor kW 3 3 3 3
Electric protection (fuse) A 16 16 16 16
Surface protection class — IP54-PP/IP 65 IP54-PP/IP 65 lift IP54-PP/IP 65 IP54-PP/IP 65
lift lift lift
Operating oil pressure Mpa 22 22 22 22
Ambient operating temperature ºC 5-50 5-50 5-50 5-50
Ambient humidity (relative) % 80.0 max 80.0 max 80.0 max 80.0 max
Generated noise level dB 74 74 74 74
Viscosity of the hydraulic oil OHHM 32 OHHM 32 OHHM 32 OHHM 32

Shipping weight kg 856 878 900 922

Maximum operating stroke HC mm 1850 1850 1850 1850
Maximum height of the arms HO mm 1985 1985 1985 1985
Minimum height of the arms HU mm 135 135 135 135
Maximum clearance of the jack mm 3863 4163 4463 4763
HL
Total height of the jack HG mm 4006 4306 4606 4906
Maximum clearance of the posts mm 3000 3000 3000 4000
BL
Maximum width of a vehicle mm 2765 2765 3765
served BH
Total width BG mm 3600 3600 4600
Length of the arm LL mm 700-1421 700-1421 700-1421 700-1421

The lifts are designed to operate indoors where they are protected against the adverse influence of
winds and where the environment in general corresponds to the Class IP 65 (RESPECTIVE LIFT)
and IP 54. (POWER PACK). It´s not possible to place lift in E-EX area.
With reference to the outside influence under standards ČSN 332000-3 (IEC 234-3:1993, HD 384.3
S1:1995, IEC 361-3/A1:1994, HD 384.3 S2:1995) = abnormal. The standards ČSN 332000-5-51
(HD 384.5.51 S2:1996, IEC 364-5-51 S1:1994) = AB8, AD4.
Note: The manufacturer reserves the right of change without prior notice.

1.4 Description
The hydraulic lifts AMI 5,5 VAN ML are intended for lifting the lightweight trucks and vans with the
total weight not greater than 5,5 tons respectively. The entire lift can be divided into the following
three subassemblies:
• steel frame
• hydraulic system
• electric equipment
Steel frame
The steel frame consists of the two vertical posts provided with the two guides. In the guides, the
lifting carriages move up and down being hooked to the piston rods of the hydraulic cylinders. The
carriages are stabilized by the pair of steel cables that guarantee the lateral symmetry of the lifting
process. Both posts are mutually connected by the horizontal cross bar in their upper parts. Under
cross bar is installated the top safety rod operated by top limit switch.. The carriages are provided with
rectangular orifices. Into these orifices, the mechanical safety locks are inserted automatically at the
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commencement of the lifting phase of the operation. Thus, the vehicle being lifted is held secure in its
position and there is no risk of the vehicle to fall off the device in case of a failure. The lifting
carriages are provided with the pair of extendable arms, which can be firmly arrested in their selected
extended position by the corresponding locking latches.

Hydraulic system
The hydraulic consists of hydraulic cylinders placed in both posts and the pipes, hoses and connector
by which is a hydraulic oil brought to the hydraulic cylinders. The tank with hydraulic oil has the
capacity for about 8 litres.
Electric equipment
All the electric equipment of the hydraulic lift are placed by the power unit instead of operating
buttons. These buttons are placed on the right post of the lift. The electric equipment meets the
conditions of the protective covering according to Class IP 54 requirements - for power pack and
IP 65 - for respective lift

1.4. HYDRAULIC AND WIRING DIAGRAM

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DESRIPTION:
N - TANK
F - SUCTION FILTR
P - PUMP
PV- SAFETY VALVE
JV – ONE WAY VALVE
RV- LOWERING VALVE
D - JET
HV- HYDRAULIC CYLINDER

2. ASSEMBLY AND INSTALLATION

The lift is delivered to the installation site in partially disassembled condition, packed into the special
transport frame. All accessories are contained in the factory packing. To assemble, anchor and set-up
the lift correctly is a rather complex task. Therefore, it is necessary that the job be entrusted to the
service team of the manufacturer. The lift should be installed only in places where the floor is made of
high quality concrete having the minimum thickness 25 cm (min. impress strength 15 MPa).
Alternative option is to set-up the lift on the two concrete foundation blocks under each post, having
dimensions 120x70 cm and sunk to the depth of 50 cm inside/80 cm outside. At the place of
installation must be available the network 3/N/PE AC 400V/230V/50Hz secured by breaker In =
25A/B.
1. MAKE MEASUREMENT AND LIFT PLACEMENT
2. CONNECT THE LEFT AN RIGHT POST BY CROSS BAR, CABLES, HYDRAULIC PIPE AND
OPERATING STEEL CABLE
3. PUT THE OIL INTO THE TANK (VISCOZITY 32 – APPROX. 8 L)
4. GO UP WITH THE LIFT WITHOUT ANY LOAD
5. ANCHOR AND PAD OUT THE LIFT INTO VERTICAL POSITION OF BOTH POSTS –
TIGHTENING MOMENT OF THE ANCHORAGE BOLTS – 150 Nm
6. LOAD THE HEAVY VEHICAL AND CHECK THE LIFTING AND LOWERING

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3. PRINCIPLES OF SAFE OPERATIONS OF THE LIFT

3.1 Operating personnel

Only a properly trained person is allowed to operate the lift. Any operator must be mentally and
physically fit and should be at least 18 years old.
3.2 Operating procedures and safety precautions during the lifting phase
The lifting carriages are in their lowermost position. In this position, the arresting safety locks of
the lift are unlocked. The arms of the lift should be stretched during vehicle drive . The lift is
symetric and therefore the centre of the lift must concur to the vehicle. The vehicle may be
positioned approximately into the middle between the two posts.

3.3 LIFTING
The arms should be moved below the vehicle and their length should be adjusted in such a way as
to make sure that the rotating supports with the rubber pads face exactly those spots that are
designated by the car manufacturer to be the ones used for lifting the vehicle above ground. The
supporting pads can be adjusted using their threaded mounting in such a way as to make their
distance from the bottom parts of the vehicle to be the same for all pads. Using the push button of
the lift, we begin to move the pads carefully and gently up while checking that the supporting
pads are heading towards the appropriate lifting spots on the chassis/body of the vehicle. If this is
not the case, we interrupt the upward motion and readjust the arms and supports as necessary. It is
also necessary to check that all the arresting levers have locked themselves and thus prevent any
undesirable rotation of the arms. If all is OK, we can continue lifting the vehicle to the desired
elevation with push button. The maximum height is determined by the circumstance that the roof
of the vehicle gets into touch with the horizontal top safety bar at the top of the lift or, that the
lifting carriages have reached their maximum top position. The lift doesn´ t have a limit switch.
So when the load is higher than different between HL – HO STOP THE LIFTING BEFORE
TOUCHING THE TOP CROSS BARR !!!!

3.4 LOWERING
The lowering phase can be commenced only after checking that there are neither any people nor
objects standing in the way of the vehicle to be lowered down. The action begins by moving
briefly the push button of the lift into the "upward" position; the vehicle is slightly lifted and the
safety locks unlock themselves. Thus, the lowering of the vehicle becomes possible by moving
the control lever of the lift into the "downward" position. The lifting carriers must reach their
lowermost position - this is the necessary condition for the arresting levers to unlock themselves.
Only after unlocking the arresting levers the lifting arms can be rotated freely and set into their
initial positions parallel with the longitudinal axis of the vehicle.

3.5 THE FORBIDEN HANDLING AND OTHER THINGS TO AVOID:

• hoisting and lowering when there is an unauthorized person within the reach of moving parts
of the lift
• overloading the lift
• operating of the lift by unauthorized person
• lifting people (being either on the jack's arms or inside the hoisted vehicle)
• leaving any objects in the vicinity of the moving parts of the lift
• to use the lift for any other purpose but lifting and lowering the vehicles
• to work on the lift when it is not mechanically secured in its position
• uneven loading of the lift's arms

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4. MONITORING THE SAFETY DEVICES

The safety devices to be monitored during the operation are the following ones:
• mechanical locks
• one-way hydraulic valve
• arms-arresting mechanism
The function of the mechanical locks can be easily monitored by the sense of hearing; the latches
produce the characteristic "ratcheting" sound on each upward movement of the lift.
The functionality of the arms-arresting mechanism is also checked before each upward motion of the
lift during the time when the vehicle is being made ready for lifting.
If the one-way hydraulic valve begins to perform poorly, the vehicle hoisted up by the jack droops
downward by more than 2% of its original height during the interval of 15 minutes. In this case, the
authorized technician must be called in.

5. MAINTENANCE

The user is obliged to see to it that the following routine is adhered to:
• Once a month: ► check that the anchor screws are tightened OK
► check that all the moving parts are properly lubricated (use MOGUL
LA2
lubricant or equivalent)
• Once every 3 years: ► entirely replace the hydraulic oil; clean the filtration sieve
Any other repairs must be carried out by the authorized technician.

5.1 STEEL CABLES TENSIONING PROCEDURE

- CABLES FIXATION IS PLACED IN UPPER PART OF CARRIAGES INSIDE THE POSTS

- THE TENSION OF THE CABLES MUST BE ADJUSTED IN SUCH A WAY AS TO ENSURE

THAT THE SAFETY LOCKS IN BOTH POSTS LOCK EXACTLY AT THE SAME TIME

- CABLE GRIPPING ARE PLACED IN TOP PART OF THE CARIAGE INSIDE THE POSTS

- WHEN YOU TIGHT THE CABLE ON THE RIGHT SIDE OF THE LIFT, THE POSITION OF THE
LEFT CARRIAGE SIDE IS INCREASED WITH THE RETURN MOTION

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self-locking nut

cable end

space for cable end holder

7. TECHNICAL INSPECTIONS

Every lift is tested in the manufacturer’s shop under EN 1493 conditions for functionality. The lift to
pass the test may not droop more than 2% of the entire upward path during the 15 minutes interval. It
is the responsibility of the user to carry out the later-day routine technical inspections. They should be
carried out in the regular intervals of 6 months. The following items must be checked during the
routine inspection:
• the functionality tests with the special emphasis on the hydraulic system and the mechanism
of the safety locks
• visual check of the structural parts of the lift with emphasis on the occurrence of cracking
welds
• check of the obligatory equipment and marking
• the even and leveled operation of the two sides of the lift

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7. TROUBLESHOOTING

7.1 Motor failure

In case this trouble manifests itself, first think to check is the electricity supply line, the main
cable, fuses and the functionality of the limit switch. There is the contact breaker in the
switchboard box that can be operated manually. If turning this breaker ON causes the electric
motor to run the problem must be located somewhere in the control circuit - cf. the schematic
wiring diagram of the electric circuitry of the lift. Very often, the sufficient remedy is to pry loose
the upper yellow cover of the horizontal bar that must be in its lowermost position (sinking into
this position by its own weight). Another think to check is the tight attachment of all the electric
cables. If these simple measures fail to revitalize the motor, call the authorized technician.

7.2 Motor works OK but the lift does not move up

Check that there is enough oil in the oil tank. Vent the hydraulic system to make sure that there
are no traces of air in the system. The venting of the air is carried out by loosening the sleeve nuts
of the hydraulic hoses leading to the both hydraulic cylinders (only the foam-free oil must be
leaking from the system). Another items to be checked are the oil filter in the tank (if dirty, it
must be washed thoroughly) and the tightness of all fittings of the hydraulic system. If the lift is
not blocked by some object in the guides of the posts or under the piston rod and it continues to
malfunction the replacement of the pump or hydraulic distributor is very likely to remedy the
situation. However, in the latter case the assistance of the authorized technician will be necessary.
7.3 The lift cannot be lowered
Check the mechanical locks; they should not be stuck inside the corresponding notches of the
arresting profiles of the lift's carriages. Another reason for failure of the lift to move down could
be excessive tension of the steel cables, some obstructions standing in the way of the carriages or
the faulty hydraulic distributor.

7.4 Other problems

If the lift moves in an intermittent manner, the likely causes are either excessively tensioned steel
cables or the presence of air in the hydraulic system. If the presence of the air in the hydraulic is
established, make several "dry" runs up and down with the lift; this causes the hydraulic system to
vent itself automatically.

8. PARTS REPLACEMENT

The only parts requiring rather frequent replacements are the rubber pads, which come into the
frequent contact with the bodies of the vehicles being served. Thy have to be replaced approximately
every six to twelve months.

9. DECOMMISSIONING THE EQUIPMENT

The individual parts of the lift are disposed of in the following manner:
- The metal parts are to be handed to a scrap metal operator
- Plastic parts which can be recycled are to be handed over to the respective recycling plants
- The lift does not contain any non-recyclable plastic parts
- The used hydraulic oil should be handed over to the oil refinery for recycling process

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10. LIST OF DELIVERED ITEMS

• Complete lift packed in the transport frame

• Dismounted kit of extension of the lifts packed on palette
• Complete documentation for the lift including this manual
• Set of extension members (8 off: 4 short, 4 long ones)

The electric cable for connecting the lift with the power supply socket must be provided by the
customer.

AUTO MOTIVE INDUSTRIAL a.s.

Sokolovská 1169, 570 01 LITOMYŠL
Tel.: +420 461 618 555
Fax.: +420 461 612 132
e-mail: [email protected]
www.automotive.cz

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